Machine and process for the production of convolutions in wire



Aug. 11, 1959 K. 2. HUSZAR MACHINE AND PROCESS FOR THE PRODUCTION OFCONVOLUTIONS IN WIRE 2 Sheets-Sheet 1 Filed Dec. 8, 1955 2 MW NM QZZWQZMM- ATTO RNEYS.

Aug. 11, 1959 K. 2. HUSZAR 2,

MACHINE AND PROCESS FOR THE PRODUCTION OF CONVOLUTIONS IN WIRE FiledDec. a, 1955 2 Sheets-Sheet 2 QM 8% mwm T2 2 m6 w ma i N, l r/// 7///w// A Q}? u mi Li SN MACHINE AND PROCESS FOR THE PRODUCTION OF CONV OLUTIONS IN WIRE Kalman Z. Huszar, Foster, Ohio Application December 8,1953, Serial No. 396,930

'5 Claims. (Cl. 140-71) My invention resides in providing an improvedmachine and process for the production of convolutions in wire,specifically an improvement in the basic machine and process disclosedin my co-pending application Serial No. 263,915, now Patent No.2,737,212.

In my said co-pending application I disclosed a machine for producingserpentine-like bends in wire which may be described as comprising acooperating pair of rotary bending elements, means for feeding a wirebetween said bending elements at a constant speed, and means forsupporting said wire in the plane containing the axes of said bendingelements. In the machine of this co-pending application the bendingelements are described as screw members or open helices of mutuallyopposite hand, each of the screw members comprising a portion having aconstant pitch and constant tooth height and an initial portion of alarger pitch and having a tooth height increasing from a minimum to aheight merging with that of the first mentioned portion. In the machineof this co-pending application means are provided for rotating the openhelices in opposite directions at such a speed that the lead of theportion of constant pitch is less than the speed of the wire. arefurther described as comprising coils, the supporting means for the wirecomprising guide members fixed within each coil, each of the guidemembers having a straight groove to receive the tips of the bends formedin the wire.

Thus, in the basic machine of my co-pending application I employ openhelices or coils, the wire is operated on in a plane containing thecenter lines or axes of the coils and special supports are provided tomaintain the wire in such plane.

The basic modifications of the machine and process shown in myco-pending application, and constituting the invention here, reside inthe use of solid worms in place of the open helices, locating the planeof operation in which the convolutions are formed in a position abovethe plane containing the center lines of the solid worms, andeliminating the extra wire supports needed to hold the wire at thecenter line of the coils.

In the machine and process of the instant invention, as is the case inthe basic apparatus and process described in my said co-pendingapplication, the wire is first fed to a forming unit comprising a pairof worms having what are termed cam and mandrel sections, such formingunit folding the wire into the basic form. A second pair of wormsreceives the wire having the basic convolutions imparted to it andconveys such wire from the forming unit to the spacing unit. The wormsof the receiving unit have the same pitch as the incoming convolutionsfrom the forming' unit. The wire is delivered from the receiving unit tothe third worms comprising the spacing unit. The worms of the spacingunit are pitched so as to deliver the spring or wire with. theconvolutions spaced as required in the final rform.

' Having now described the invention in a general way, I shall describethat particular apparatus and process which I have found to produce thebest results and Which States Patet Also, the open helices ICE 2 isfully set forth in the following specification and with reference to theaccompanying drawings, in which drawings like numerals are employed todesignate like parts throughout the same and in which:

Figure l is a plan view, with par-ts broken away, of the basic machinerycomprising the apparatus of this invention,

Figure 2 is a greatly enlarged plan view of the mechanism shown at theright side of Figure 1,

Figure 3 is a section taken on the line 33 of Figure 1,

Figure 4 is a section taken on the line 44 of Figure 3,

Figure 5 is a section taken on the line 55 of Figure 3,

Figure 6 is a section taken on the line 6-6 of Figure 3,

Figure 7 is a perspective view of a wire guiding element employed in theapparatus of this invention,

Figure 8 is a section taken on the line 88 of Figure 3, and

Figure 9 is a section taken on the line 9-9 of Figure 3.

In addition to the basic modifications above generally described, andwhich will be set forth in greater detail below, the present inventionalso includes several innovations with respect to the handling of thewire. These will be described in detail as the description proceeds.

Referring first to Figures 1 and 3 I have shown the wire 20 as comingfrom a reel or source of supply which is not shown in the drawings. Thiswire first passes through a plurality of straightening rolls 21, 22, 23and 24. These straightening rolls are suitably mounted in a bracket 25mounted on the base 26 of the machine.

The wire then passes over the first of a pair of measuring rolls 27 and28. Each of these rolls has a groove to receive the wire and each worksin conjunction with a pressure roll 29 and 30 respectively. Each of therolls 29 and 30 is mounted on a separate shaft 31 or 32 respectively,see also Fig. 8, having suitable bearings in a pivoted arm provided inthe machine as will be described. One such arm, for the roll 29, isindicated at 33. This arm 33 is pivoted to a stand 34. The combinedweights of the arm 33, shaft 31 and roll 29 act to urge the wire intocontact with the roll 27. If additional pressure is desired it may beobtained in the general manner indicated in connection with the arm 43and roll 40 to be described, see also Figure 3.

The measuring rolls 27 and 28 are mounted on a shaft 35 which hassuitable bearings in brackets 36. It will be observed that the measuringroll 28 is pinned to the shaft 35 as indicated at 37 while the measuringroll 27 is mounted on a threaded portion 38 of the shaft 35. The reasonand function of this construction will be described shortly.

The Wire 20 is pulled through the straightening rolls and the measuringrolls by the draw or pull rolls 39 and 40. The draw roll 39 is mountedon the driven shaft 41 carried on an arm 43 which is pivoted at 44 to abracket 45 based on the'frame member 26. The fiee end of arm 43 isprovided with a working surface 46 against which the cam surface 47 mayoperate. This cam surface 47 is fixed on a shaft 48 which may besupported from a pair of rods 49. A lever 50 is connected to the shaft48 and it will be apparent that by operation of this lever the cam 47may be made to force the arm 43 and its vroll 40 into the desiredpressure contact with the wire 20 and driven pull roll 39. Theuppe'r'pu'll roll 40: is mounted on a shaft 51 which is received by thebearing 42"earlier described.

It should be pointed out that the operating surfaces of the, rolls39 and40 are tapered as indicated at 39a and 40a respectively, see especiallyFigure 9;

As is best seen in Figure 3 it will be observed that the mechanism sofar described is so arranged that the wire 20 is drawn through thestraightening rolls 21through 24' and the measuring roll 27 by the drawrolls 39' and 40 so as to form a large loop the beginning of which isdesignated at 20a and the ending of which is indicated at 20b. Uponcompletion of the formation ofthisloop as at 20b the wire,20 then passesover the measuring roll ZS'and its cooperating pressure r'oll 30. Powerto the draw roll 39 is supplied through the driven shaft 41 from thedrive shaft 52 by the gears 53 and 54 as shown in Figure 1. When thewire 20 leaves the rolls 28 and 30 it passes under an idler mechanism 55and through a pair of guide pulleys 56 and 57 to the forming unit of themachine. These guide pulleys are mounted in a plate 101 which may bescrewed on a casting 75 provided in themachine. A strap 102 may be fixedto this casting. The screw 103 passes into this strap while the screws104'are received in the casting itself.

I have found it very desirable to maintain'the large loop having thesections 20a and 20b'just described. I find that this loop may bemaintained in spite of fluctuations in the speed of the wire beingreceived at the forming unit by the arrangement of the rolls 27 and 28and the rolls 39 and 40. If, for example, the wire being fed into theforming unit should be moving faster than normal it will necessarilyfollow that the measuring roll 28 will also be moved faster. When somoved the shaft 35, which is turning clockwise as viewed in Figure 3,will also be moved faster in view of the fact that the measuring roll 28is secured to this shaft. This in turn will cause the measuring roll 27to shift to the left, as viewed in Figure 8, on the threaded portion 38of the shaft 35. When the measuring roll 27 shifts to the left as justdescribed, or in other words moves closer to the measuring roll 28, thewire 20 is moved from the position shown in Figure 9, between thetapered surfaces 39a and 40a of the draw rolls 39 and 40 respectively,to a left hand position as viewed in this figure. It will be apparentthat when the wire 20 so moves with respect to the tapered surfaces justdescribed the result will be that the draw rolls 39 and 40 will pull thewire 20 between the measuring roll 27 and its pressure roll 29 at afaster rate. This, of course, will supply the additional wire needed tomaintain the loop and to compensate for the greater amount of wire beingfed into the forming unit. It will be obvious to those skilled in theart that should the wire be taken up by the forming unit at a slowerspeed, the various mechanisms just described will operate in reversesequence so that the loop does not become too large.

Considering now the mechanism for imparting the desired bend to thewire, I provide a pair of shafts 58 and 59 which are driven throughsuitable mitre gears 60 and 61 which mesh with corresponding gears 62and 63 fixed on the shaft 52. These shafts 58 and 59 are arranged torotate towards each other in the manner illustrated in Figures 4, and 6.It will also be apparent to those skilled in the art that the shafts 58and 59 will be provided with suitable hearings in brackets based on thebase member 26 as illustrated in Figures 1 and 3.

The shafts 58 and 59 carry the forming unit comprised of the worms 64and65, the receiving unit comprised of the Worms 66 and 67, and thespacing unit comprised of worms 68 and 69.

As the wire 20 enters the forming unit defined by the. members 64 and65, it passes over an; arm 70mounte on'a-shaft 71 and having a pair ofside guidebrackets 72, 73. Since the arm 70 will oscillate rapidly Ihave found it desirable to mount the rod 71 on a ball bearing 74provided in the casting 75 located on the base member 26 as best seen inFigure 3. The detailed arrangement of the arm 70 is perhaps best seen inFigure 7 and also in the left hand side of Figure2. The upper end of rod71 has a bearing in the plate 101. The arm 70 extends through an openingin the casting 75.

Each of the worms 64 and 65 comprising the forming unit for impartingthe basic serpentine convolutions to the wire 20 includes a first or camsurface and a second or mandrel surface. It is important that the wirebe introduced between the members 64 and '65 above the center line ofsuch members and at a sutficient relatively constant speed to causebuckling of the wire. The fact that the Worms 64 and 65 are solid andrevolving towards one another will keep the wire 20 from popping out ofthe bite defined by the cooperating worms 64 and 65 and their variouscam surfaces and mandrel surfaces as will be described.

The cam sections 64a and 65a have a greater pitch than the mandrelsections 64b and 65b. The buckling imparted to the wire 20 by reason ofits rate of speed between the bite of the members 64 and 65 iscontrolled by the action of the cam surfaces 64a and 65a in folding thebuckling wire alternately to the left and right. The cam surface 64a,for example, will engage the wire 20 and move it against the mandrelsection 6511 of the worm 65 after which the cam portion 65a'of the worm65 will engage this wire 20 and move it about the mandrel section 64b ofthe worm 64, this process continuing alternately.

Since the wire is introduced into the forming unit above the centerlines of the worms 64 and 65 it is not necessary to provide the sidesupports for the wire which were an important part of the arrangementshown in my said co-pending application wherein the corresponding wormswere coils having open helices and wherein the wire was introduced atthe center line of these coils. The elimination of these extra sidesupports by making the worms solid and by introducing the wire abovetheir center lines constitutes an important part of this invention.

From the foregoing it will be apparent that the worms 64 and 65, withtheir operating cam surfaces 64a and 65a and mandrel sections 64b and6512, will impart basic convolutions to the wire 20. As the wire 20leaves this forming unit the convolutions imparted thereto will bereceived by the worms 66 and 67 of the receiving section. The Worms 66and 67 are provided with the same pitch as the incoming convolutions.The basic function of the Worms 66' and 67 is to convey the wire havingthe con volutions formed therein by the worms 64 and 65 to the spacingsection comprised of the worms 68 and 69. Also, the worms 66 and 67 willtake up any back pressure that occurs as will be described.

The worms 68 and 69 of the spacing unit are pitched so as to deliver theWire with the convolutions spaced as required in the finished article.These worms 68 and 69 are so grooved as to im'part'a desired degree ofconvolution to the wire such that when the wire is free of the spacingunit it will spring back only to a controlled, predetermined extent.Since the grooves of the worms 68 and 69 are designed to impart an overbend to the convolutions it will 'be apparent that back pressure willarise. An important function of the worms 66 and 67 is to take up thisback pressure. Were it'not for the worms 66 and 67 with such backpressure would have to be taken care of by the worms 64 and'65 of theforming unit and this would not be desirable for it would causefluctuations in the basic convolution being imparted to the wire by theworms of such forming unit.

In order to insure optimum results I find that it is desirable to employauxiliary support means for the strip of wire as it is moved from thereceiving unit comprised of the worms 66 and 67 to the spacing unitcomprised of the worms 68 and 69. Such auxiliary support means comprisesa pair of parallel plates 76 and 77. The plate 77 may be screwed orotherwise fastened within the bottom of a U-shaped channel cut within anupstanding bracket 78 based on the main frame member 26. The plate 76may be screwed to a cross member 79 which bridges the aforementionedchannel cut within the bracket member 78. The provision of the plates 76and 77, which are spaced apart just sufficient to receive the convolutedwire, insures proper maintenance of the wire above the center line ofthe various worms constituting the forming unit, the receiving unit andthe spacing or finishing unit.

Perhaps the functions of the various worms are best seen at the righthand side of Figure 2. As shown in this figure the cam section 65a ofthe worm 65 has just completed a bend of the wire about the mandrelsection 64b of the worm 64. Continuedrotation of the worms 64 and 65will result in the cam section 64a bending the wire 20 about the mandrelsection 65b of the worm 65. As this is done the arm 70 will pivot aboutthe rod 71 to properly guide the buckling wire 20. The mandrel sections64b and 65b impart the basic convolution or serpentine-like bend to thewire 20.

As the wire moves forward the convolutions imparted to it by the formingmembers 64 and 65 are received by the grooves of the worms 66 and 67.These worms do not impart any further bend to the convolutions of thewire. They simply advance the convoluted wire to the third set of worms68 and 69, also serving, however, to take up any back pressure caused bythe work done by the worms 68 and 69.

These worms 68 and 69 have grooves sufficient to further bend theserpentine-like convolutions of wire. In fact, these members 68 and 69actually force the wire to assume greater serpentine bends than areactually desired in the finished product. The extent to which the wire20 is bent further than that desired in the finished product depends onthe resiliency of the wire and its ability to spring back once pressuresare relieved. The idea is to sufiiciently bend the wire 20 by themembers 68 and 69 as to give the desired convolutions in the finishedwires as at 200 after the wire has sprung back to its free conditionfollowing release from the worms 68 and 69.

Also, as stated, the wire is given additional support between thereceiving unit comprised of the worms 66 and 67 and the spacing unitcomprised of the worms 68 and 69. One of the reasons for this is thatthe step of imparting an over bend to the convolutions in the wire 20causes the speed of wire feed to 'be slowed down, this not only puttingback pressure on the worms 66 and 67 but also tending to cause the wireto buckle in a ventical plane. The guide members 76 and 77 prevent thisand serve to maintain the wire within the bite of the various wormsabove their center axes.

In operation then, it will be observed that the wire 20 is pulled from asuitable supply reel, not shown, by the draw or pull rolls 39 and 40,the roll 39 being driven through gears 54 and 53 from the drive shaft52, such roll 39 being mounted on the driven shaft 41 which carries thegear 54.

The wire 20 as pulled by the rolls 39 and 40, is brought through aplurality of straightening rolls 21 through 24 and a first pair ofmeasuring and pressure rolls 27 and 29. The wire is then caused to forma large loop as indicated at 20a and 20b, such wire then passing betweena second pair of measuring and pressure rolls 28 and 30 respectively.

Continued actuation of the pull roll 39, in cooperation with the roll 40which bears against the wire passing over the pull roll 39, whichpressure may be regulated by the cam 47, bearing surface 46, shaft 48and lever 50, serves to feed the wire 20 past idler mechanism 55 andbetween a pair of pulleys 56 and 57. This wire also passes over an arm70 having upstanding guide members 72 and 73.

As the wire 20 enters the forming unit comprised of the worms 64 and 65,and the serpentine-like convolutions are imparted thereto by cooperationof the cam and mandrel sections of these forming worms, the arm 70 willoscillate as the wire is buckled back and forth alternately over thevarious mandrel sections. Further movement of the wire sends the firstformed convolutions through the receiving worms to the finishing wormswhere a greater degree of bend is imparted to the wire, such final bendbeing sufficient to give the desired product when the wire is free toassume its released position. As stated, the worms 66 and 67 serve totake up the back pressure while the plates 76 and 77 prevent buckling ofthe wire in a vertical plane while the finishing bends are beingimparted thereto.

In addition it will be observed that the rolls 27 and 28 are designed tocooperate with the rolls 39 and 40 so as to maintain the large loop ofwire in substantially constant condition. A speeding up, for example, ofthe wire being received by the forming unit will'cause the roll 28 thewire 20 moves towards the high side of the move to the left asviewed inFigure 8 or, in other words, towards the roll 28. When the roll 27 movestowards the roll 28 the wire 20 moves toward the high side of thetapered surface 39a of the pull roll 39 with the result that the wire 20is pulled from the source at a greater rate. Since the forming unit is,in this example, using the wire 20 at a greater rate it is necessary tospeed up the feed from the supply roll in order to maintain the largeloop. It will be apparent that when the converse happens the parts areso arranged as to slow up the feed and still maintain the loop asdesired.

In its broader aspects, my invention as herein described resides in theprovision of solid worms rather than the open coils previously used, inthe elimination of the lateral support employed in my prior device andin maintaining the wire at a position above the center line of thevarious worms which act to give the desired serpentine convolutions tothe wire. In addition the specific means for providing and maintainingthe loop of material mentioned are believed novel as Well as are theauxiliary supports provided between the second and third pairs ofoperating worms.

It will be apparent to those skilled in the art that modifications maybe effected in this invention without departing from the scope andspirit thereof. It will be further understood that while I have shown myinvention as embodied in specific structure, such showing is exemplaryonly and I do not intend to be limited to the specific structure shownexcept insofar as it is positively recited in the subjoined claims.

Having thus described my invention, what I claim as new and what Idesire to protect by United States Letters Patent is:

1. In a machine for producing serpentine-like bends in wire: acooperating pair of parallel rotary bending elements; means for feedinga wire between said bending elements at a constant speed; said bendingelements comprising solid worms; each of said worms comprising aninitial cam portion having a relatively large pitch and a tooth heightincreasing from a minimum to a maximum, and a mandrel portion of asmaller and constant pitch and a constant tooth height equal to saidmaximum; said feed means introducing said wire between said worms abovethe center lines thereof; and means for rotating said worms at such aspeed that the lead of said portion of constant pitch is less than thespeed of said wire.

2. A machine for producing serpentine-like bends in wire comprising: acooperating pair of horizontal parallel rotary bending elements; meansfor feeding a wire between said bending elements at a constant speed;said bending elements comprising solid worms of mutually opposite hand;each of said solid worms comprising an initial cam portion having arelatively large pitch and a tooth height increasing from a minimum to amaximum,

lines of said solid worms; and means for rotating said solid -worms inopposite directions at such a speed that the lead of said mandrelportion of constant pitch is less than thespeed of said Wire.

3. The machine of claim 2 including a pair of solid worms having helicalgrooves of smaller pitch than "that of the serpentine bends imparted tosaid 'Wire by-said first mentioned solid worms, said second mentionedpair of Worms being spaced axially from said first mentioned worms, saidgrooves receiving said bendsafter said wire leaves said first mentionedWorms, and means to rotate said second mentioned worms.

4. The machine of claim 3 including another pair of solid worms havinghelical grooves therein, said last mentioned pair of worms beingpositioned "between said first two mentioned pair of wormsand free ofeach, said last mentionedpair of worms "having groovesof a pitchsubstantially equal to that of said serpentine bends, and

means to rotate said last mentioned-pair of worms.

5. The machine of claim 4 including a pair of plates to support saidwire from above and below between the last mentioned and secondmentioned pair of worms.

References Cited in th file, of this patent UNITED STATES PATENTS933,890 Cummings Sept. 14, 1909 1,327,467 Griner Jan. 6, 1920 1,339,104Cooke May 4, 1920 1,345,445 Johnson July 6, 1920 1,399,098 Winter Dec.6, 1921 1,615,666 Wright Jan. 25, 1927 2,333,278 Truesdail Nov. 2, 19432,349,750 Peterson H. May 23, 1944 2,378,058 Blumensaadt June 12, 19452,491,228 Swift Dec. 13, 1949 2,582,576 Zweyer Jan. 15, 1952 FOREIGNPATENTS 106,894 Australia Mar. 23, 1939

